This paper documents the geometric optimization of a three dimensional micro-channel heat sink with hydraulic diameter greater than 10μm. Two methods of analysis were used to perform the optimization; approximate relation using scale analysis and numerical method using a finite volume code. The micro-channel heat sink is treated as a combined unit. The effect of void fraction and pressure drop on the aspect ratio, hydraulic diameter and peak temperature on the micro-channel heat sink were investigated. The numerical simulation was carried out on a unit cell with volume of 0.9 mm3 and pressure differences between 10 kPa and 75 kPa. The optimal configurations obtained numerically were compared with those obtained from approximate relationship using scale analysis and the trends are found to be in good agreement.

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